Closed-loop robotic deposition of material

ABSTRACT

A robot system is configured to fabricate three-dimensional (3D) objects using closed-loop, computer vision-based control. The robot system initiates fabrication based on a set of fabrication paths along which material is to be deposited. During deposition of material, the robot system captures video data and processes that data to determine the specific locations where the material is deposited. Based on these locations, the robot system adjusts future deposition locations to compensate for deviations from the fabrication paths. Additionally, because the robot system includes a 6-axis robotic arm, the robot system can deposit material at any locations, along any pathway, or across any surface. Accordingly, the robot system is capable of fabricating a 3D object with multiple non-parallel, non-horizontal, and/or non-planar layers.

BACKGROUND OF THE INVENTION Field of the Invention

Embodiments of the present invention relate generally to robotics and,more specifically, to closed-loop robotic deposition of material.

Description of the Related Art

A three-dimensional (3D) printer is a device for fabricating real-world3D objects based on simulated 3D models. A software applicationexecuting on a computer system typically interfaces with the 3D printerand coordinates all aspects of printing, including processing the 3Dmodels and issuing printing commands to the 3D printer.

To fabricate a 3D object, the software application first processes the3D model to generate a set of slices. Each “slice” is a differenttwo-dimensional (2D) cross-section of the 3D model. The softwareapplication generates each slice by computing the intersection between a2D plane and the 3D model at a specific depth along a vertical axisassociated with the 3D model. A given slice thus indicates a set of X,Y, Z coordinates where the 3D model occupies space. For a particular X,Y, Z coordinate, the Z coordinate indicates the height of the slice,while the X and Y coordinates indicate a planar location within theslice. As a general matter, each slice in the set of slices issubstantially horizontal and also substantially parallel to an adjacentslice. Taken as a whole, the set of slices represents the overalltopology of the 3D object to be fabricated and indicates the volume ofmaterial needed to print the 3D object.

After generating the set of slices, the software application configuresthe 3D printer to iteratively deposit material based on the X, Y, Zcoordinates included within each slice. Specifically, the 3D printerdeposits material one slice at a time at the particular X, Y, Zcoordinates where the 3D object occupies space. The material depositedacross all X, Y, Z coordinates associated with a given slice forms alayer of material that resembles each slice. Material for eachsubsequent layer is deposited on top of a previous layer andsubstantially parallel to that previous layer. When the 3D printer hasdeposited material for all slices, the 3D object is complete. Although3D printing has revolutionized fabrication of 3D objects, thefundamental approach described above suffers from two primary drawbacks.

First, conventional 3D printers and corresponding software applicationsoperate in a strictly open-loop capacity and therefore are not able torespond to feedback. Consequently, conventional 3D printers and theassociated software applications typically cannot tolerate faults,deviations, or other unforeseen events that may arise or be experiencedduring the printing process. For example, suppose a thermoplastics 3Dprinter were to deposit a bead of material that had a density thatexceeded the expected density for the material. Because of the higherdensity, the bead would take longer than expected to harden, which wouldthen cause one or more subsequent layers of material to be depositedincorrectly when printed. Accordingly, when the 3D object completedprinting, the object would sag near the location of the bead and appearshorter than expected.

Second, conventional 3D printers are mechanically constrained and candeposit material only in substantially parallel, horizontal layers.Consequently, conventional 3D printers cannot fabricate 3D objectshaving certain types of geometry. For example, a conventional 3D printerwould not be able to easily fabricate a 3D object with an extendedoverhanging portion, because the overhanging portion would lack physicalsupport from any underlying layers of material.

As the foregoing illustrates, what is needed in the art are moreeffective techniques for fabricating 3D objects.

SUMMARY OF THE INVENTION

Various embodiments of the present invention set forth acomputer-implemented method for fabricating a three-dimensional (3D)object, including causing a deposition tool to deposit a first portionof material proximate to a first target location, determining a firstdistance from the first portion of material to the first targetlocation, updating a second target location based on the first distanceto generate an updated second target location, and causing thedeposition tool to deposit a second portion of material proximate to theupdated second target location.

At least one advantage of the techniques described herein is that therobot is capable of tolerating and compensating for a wide variety ofpotential faults, thereby increasing the likelihood of fabricating a 3Dobject that meets design specifications.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 illustrates a system configured to implement one or more aspectsof the present invention;

FIG. 2 illustrates various data and processing stages implemented by thecontrol application of FIG. 1, according to various embodiments of thepresent invention;

FIG. 3 illustrates a guide curve along which the robot system of FIG. 1deposits material, according to various embodiments of the presentinvention;

FIG. 4 is a more detailed illustration of the guide curve of FIG. 3,according to various embodiments of the present invention;

FIG. 5 illustrates a deposition plan the robot system of FIG. 1 executesto fabricate branched structures, according to various embodiments ofthe present invention;

FIGS. 6 and 7 illustrate how the robot system of FIG. 1 follows adeposition plan to fabricate a truss structure, according to variousembodiments of the present invention;

FIG. 8 is a flow diagram of method steps for fabricating a 3D object viaa closed-loop control process, according to various embodiments of thepresent invention;

FIG. 9 is a flow diagram of method steps for fabricating a branchedstructure based on a set of guide curves, according to variousembodiments of the present invention;

FIG. 10 illustrates how the robot system of FIG. 1 deposits a weld beadat a target location, according to various embodiments of the presentinvention;

FIG. 11 illustrates how the robot system of FIG. 1 adjusts thedeposition of weld beads to compensate for deviations from a guidecurve, according to various embodiments of the present invention;

FIGS. 12A-12C illustrate various circuitry and data outputs formonitoring a welding process, according to various embodiments of thepresent invention;

FIG. 13 illustrates a set of coordinate systems associated withdifferent components of the robot system of FIG. 1, according to variousembodiments of the present invention;

FIG. 14 illustrates relative positioning between an optical device and a3D object under weld, according to various embodiments of the presentinvention;

FIG. 15 illustrates how the robot system of FIG. 1 positions an opticaldevice relative to a 3D object under weld to improve data capture,according to various embodiments of the present invention;

FIG. 16 illustrates how the robot system of FIG. 1 locates a previouslydeposited weld bead, according to various embodiments of the presentinvention;

FIG. 17 illustrates how the robot system of FIG. 1 determines adeposition location for a weld bead, according to various embodiments ofthe present invention;

FIG. 18 illustrates how the robot system of FIG. 1 follows a guide curvebased on previously deposited weld beads, according to variousembodiments of the present invention;

FIG. 19 is a screen capture that illustrates the real-time output of therobot system of FIG. 1 during welding, according to various embodimentsof the present invention;

FIG. 20 is a flow diagram of method steps for fabricating a 3D objectbased on real-time optical data, according to various embodiments of thepresent invention;

FIG. 21 is a flow diagram of method steps for determining a weldlocation based on real-time optical data, according to variousembodiments of the present invention;

FIGS. 22A-22B illustrate the robot system of FIG. 1 depositing materialalong non-horizontal layers of a 3D object, according to variousembodiments of the present invention;

FIGS. 23A-23B illustrate the robot system of FIG. 1 depositing materialalong non-parallel layers of a 3D object, according to variousembodiments of the present invention;

FIGS. 24A-24B illustrate the robot system of FIG. 1 depositing materialalong non-planar layers of a 3D object, according to various embodimentsof the present invention;

FIG. 25 illustrates the robot system of FIG. 1 depositing material alongnon-horizontal, non-parallel, and non-planar layers of a 3D object,according to various embodiments of the present invention;

FIGS. 26A-26B illustrate the robot system of FIG. 1 adjusting afabrication plan in real-time based on local deviations in a 3D object,according to various embodiments of the present invention;

FIG. 27 is a flow diagram of method steps for fabricating a 3D objectusing different deposition techniques, according to various embodimentsof the present invention; and

FIG. 28 is a flow diagram of method steps for fabricating a 3D object tomeet a set of design objectives, according to various embodiments of thepresent invention.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth toprovide a more thorough understanding of the present invention. However,it will be apparent to one of skill in the art that the presentinvention may be practiced without one or more of these specificdetails.

System Overview

FIG. 1 illustrates a system configured to implement one or more aspectsof the present invention. As shown, a robot system 100 includes a robot110 configured to generate a three-dimensional (3D) object 120. Robot110 may be any technically feasible type of robot capable of operatingin three dimensions. In the embodiment shown in FIG. 1, robot 110 is a6-axis robotic arm. Robot 110 includes a deposition tool 112 and anoptical device 114.

Deposition tool 112 may be any technically feasible implement configuredto output material, including a fused deposition nozzle, a fusedfilament device, a welder, and so forth. Deposition tool 112 isconfigured to deposit material onto 3D object 120 to fabricate 3D object120. In the embodiments discussed herein, deposition implement 112 is ametal inert gas (MIG) welder configured to deposit weld beads in orderto fabricate 3D object 120. Optical device 114 is a sensor configured tocapture frames of video data related to the deposition process performedby deposition tool 112. In practice, optical device 114 is a videocamera, although other types of sensors fall within the scope of thepresent invention, including audio sensors, among others. In oneembodiment, optical device 114 is a laser scanner configured to generatea 3D point cloud of geometry data.

Robot 110 is coupled to a computing device 130. In operation, computingdevice 130 receives various data signals from robot 110, includingfeedback signals, sensor signals, and so forth, and then processes thosesignals to generate commands for controlling robot 110. Computing device130 transmits the commands to robot 110 to cause robot 110 to fabricate3D object 120. Computing device 130 includes a processor 132,input/output (I/O) devices 134, and a memory 136, as shown.

Processor 132 may be any technically feasible form of processing deviceconfigured process data and execute program code. Processor 132 couldbe, for example, a central processing unit (CPU), a graphics processingunit (GPU), an application-specific integrated circuit (ASIC), afield-programmable gate array (FPGA), any technically feasiblecombination of such units, and so forth.

I/O devices 134 may include devices configured to receive input,including, for example, a keyboard, a mouse, and so forth. I/O utilities134 may also include devices configured to provide output, including,for example, a display device, a speaker, and so forth. I/O utilities134 may further include devices configured to both receive and provideinput and output, respectively, including, for example, a touchscreen, auniversal serial bus (USB) port, and so forth.

Memory 136 may include any technically feasible storage mediumconfigured to store data and software applications. Memory 136 could be,for example, a hard disk, a random access memory (RAM) module, aread-only memory (ROM), and so forth. Memory 126 includes a controlapplication 138 and a database 140. Control application 138 is asoftware application that, when executed by processor 132, implements aclosed-loop control process that is described in greater detail below inconjunction with FIG. 2.

FIG. 2 illustrates various data and processing stages implemented by thecontrol application of FIG. 1, according to various embodiments of thepresent invention. As shown, a closed-loop control process 200 includesa code generator 210, robot 110, 3D object 120, optical device 114, andcomputer vision processor 220.

Before fabrication begins, code generator 210 receives fabrication data202. Fabrication data 202 defines 3D object 120 and/or defines aprocedure for generating 3D object. For example, fabrication data 202could include a 3D model of 3D object 120. Alternatively, fabricationdata 202 could include a set of guide curves that robot 110 would followduring the deposition process in order to fabricate 3D object 120. Codegenerator 210 processes fabrication data 202 to generate control code204. Control code 204 generally specifies various actions for robot 110to perform, and specifically indicates a set of target locations whererobot 110 should deposit material. For example, control code 204 couldinclude G-code for performing different operations as well as a set ofX, Y, Z coordinates where robot 110 should deposit weld beads.

During fabrication, robot 110 executes control code 204 to performmaterial deposition on 3D object 120. Simultaneously, optical device 114captures real-time video of that material deposition to generate frames206 of video data. Computer vision processor 220 processes these framesto generate tracking data 208. Computer vision processor 220 implementsa technique known in the art as “template matching” to track specificlocations on 3D object 120 where robot 110 deposits material. Computervision processor 220 includes these locations in tracking data 208 andtransmits this data to code generator 210.

Code generator 210 processes tracking data 208 and compares the specificlocations where robot 110 deposited material to the set of targetlocations where robot 110 was instructed to deposit material. Codegenerator 210 analyzes the difference between each deposition locationand the corresponding target location, and then updates control code 204to compensate for those differences. In practice, numerous factors mayprevent robot 110 from depositing material at the precise targetlocations set forth in control code 204. For example, robot 110 and/ordeposition tool 112 could be subject to process-voltage-temperature(PVT) variations, including those related to material impurities,voltage surges, heating or cooling inconsistencies, and so forth.

FIGS. 3-9 describe in greater detail various techniques that robotsystem 100 implements in order to fabricate 3D objects.

Fabricating 3D Objects

FIG. 3 illustrates a guide curve along which the robot system of FIG. 1deposits material, according to various embodiments of the presentinvention. As shown, a plot 300 includes a Y axis 302 and a Z axis 304.Plot 300 includes exemplary fabrication data 310 that includes a guidecurve 312. Guide curve 312 indicates a fabrication pathway that robot110 should follow during material deposition. Vertices V0, V1, V2 and V3are disposed at intervals along guide curve 312. Each vertex is a targetlocation where robot 110 should deposit material. Tangent vectors T1,T1, T2, and T3 are also disposed along guide curve 312 and associatedwith vertices V0, V1, V2, and V3, respectively. Each tangent vector istangent to guide curve 312 at the corresponding vertex. Robot system 110is configured to generate the set of vertices and tangent vectors basedon fabrication data 310 and/or update those vertices and vectors basedon real-time feedback. Robot system 110 may then generate or updatecontrol code 204 for robot 110 by processing these vertices and tangentvectors to compensate for deviations from guide curve 312. This approachis illustrated in FIG. 3 in contrast to a conventional approach 320,where layer upon layer of material is deposited without applying anycompensation.

In one embodiment, robot system 100 implements equation 318 tosuccessively generate vertices and tangent vectors during fabrication.To generate a given vertex, robot system compares a previous depositionlocation to the target location associated with that depositionlocation. Robot system 100 may rely on computer vision processor 220 todetermine the previous deposition locations, as described above. Then,robot system 100 corrects a subsequent target location based on thedifference between the previous deposition location and thecorresponding target location.

More specifically, to evaluate equation 314, robot system 100 adds topoint a, a Vector, T, that has been scaled by a parameter, t or ti. Theresult of the bottom portion of equation 318 is, therefore, local to aand in order to drive robot 110 must be re-located with respect to theorigin, A0; the second term of equation 318 effects this relocation.Once a suitable pixel location is found for the next weld, robot system100 finds the next closest pixel location, At, and parameter, ti+1,along the guide curve. This repeats until the guide curve has beenprinted or becomes irrelevant, at which time the next guide curve in asequence is used. Although equation 318 is vector based, any parametricequation for a circle, curve, and so forth falls within the scope of theinvention. This approach is described in greater detail below inconjunction with FIG. 4.

FIG. 4 is a more detailed illustration of the guide curve of FIG. 3,according to various embodiments of the present invention. As shown, thedeposition of material onto 3D object 120 generally follows guide curve312. In particular, robot 110 is configured to deposit material atdiscrete locations between vertices V0 through V3 in a manner thatcauses 3D object 120 grow along a smooth pathway between those vertices.

In embodiments where deposition tool 112 is a MIG welder, robot system100 may deposit a sequence of weld beads at target locations that residebetween adjacent vertices, thereby interpolating between vertices. Indoing so, robot system 100 tracks the deposition location of each weldbead using the computer vision techniques described above. For a givenweld bead, robot system 100 computes the distance between the weld beadand a subsequent vertex, and then adjusts intermediate target locationsto progress towards that subsequent vertex. As shown, robot system 100determines weld bead location V2 i and distance between V2 i and thesubsequent vertex, V3. Robot system 100 may then adjust one or moretarget locations that reside between V2 i and V3 so that upon reachingV3, robot system 100 deposits a weld bead proximate to V3. In thismanner robot system 100 follows guide curve 312.

The above techniques may be implemented with any technically feasibletype of deposition tool and with any technically feasible technique fortracking deposition locations. For example, deposition tool 112 could bea fused-deposition modeling nozzle that ejects plastic filaments, whileoptical device 114 could be an infrared sensor configured to track heatsignatures. With any such approach, robot system 100 is capable offabricating highly complex structures due, at least in part, to havingsix degrees of freedom. Furthermore, robot system 100 is capable offabricating such structures with a high degree of accuracy because ofthe closed-loop deposition technique described thus far. FIGS. 5-7discuss how robot system 100 fabricates branched structures such as 3Dtrusses.

FIG. 5 illustrates a deposition plan the robot system of FIG. 1 executesto fabricate branched structures, according to various embodiments ofthe present invention. As show, timeline 500 includes deposition plan510 displayed against time axis 502 and Z axis 504. Deposition plan 510indicates a set of vertices V0, V1, V2, V3, V4, V5, V6, and V7 at whichrobot system 100 should deposit material in order to generate 3D object120. In addition, deposition plan 510 also indicates structuralrelationships between those vertices. For example, deposition plan 510indicates that V0 is connected to V1, V1 is connected to V2 and V3, V3is connected to V4 and V5, and V4 and V5 are connected to V6 and V7,respectively. Each such connection may be associated with a differentguide curve that mathematically describes a fabrication pathway forrobot system 100 to follow during deposition. Code generator 210,discussed above in conjunction with FIG. 2, is configured to generatedeposition plan 510 when translating fabrication data 202 into controlcode 204.

As also shown, deposition plan 510 is broken down into separatebranches. Branch 512 defines a connection between V0 and V1. Branch 514includes branch 512 and other branches that connect V1 to V2 and V3.Branch 516 defines a connection between V1 and V2, while branch 518defines a connection between V1 and V3. Branch 518 includes a portion ofbranch 514 and also includes other branches that connect V3 to V4 andV5. Branch 520 defines a connection between V3 and V4 and also includesanother branch that connects V4 and V6. Branch 522 defines a connectionbetween V3 and V5 and also includes another branch that connects V5 toV7. Branch 524 defines the connection between V4 and V6, while branch526 defines the connection between V5 and V7.

In order to execute deposition plan 510, robot system 100 progressessequentially from each vertex to a subsequent vertex and fabricates aconnection between those vertices in the order shown. In doing so, robotsystem 100 follows the particular guide curve associated with eachrespective connection. One advantage of the deposition plan shown isthat robot system 100 may avoid collisions between deposition tool 112and portions of 3D object 120 during fabrication. When generatingdeposition plan 510, code generator 210 may implement any technicallyfeasible optimization algorithm to maximize the efficiency with whichrobot system 100 fabricates 3D object 120, including path optimizationtechniques, among others.

Robot system 100 executes deposition plans such as that shown here inorder to generate complex structures such as trusses, as described byway of example below in conjunction with FIGS. 6-7.

FIG. 6 illustrates an example of how the robot system of FIG. 1 followsa deposition plan to manufacture a truss structure, according to variousembodiments of the present invention. As shown, truss 600 includesvertices V0 through V7. In order to fabricate truss 600, robot system100 executes a deposition plan that involves fabricating truss memberssequentially for different truss portions. In particular, to generatetruss portion 602, robot system 100 fabricates truss members connectingV0, V2, and V3 to V4. To generate truss portion 604, robot system 100fabricates truss members connecting V1, V2, and V3 to V5. To generatetruss portion 606, robot system 100 fabricates truss members connectingV2, V4, and V5 to V6. Finally, to generate truss portion 608, robotsystem 100 fabricates truss members connecting V3, V4, and V5 to V7.

Robot system 100 may implement a particular technique for generatingeach such truss portion that is described in greater detail below inconjunction with FIG. 7.

FIG. 7 illustrates in greater detail the example of FIG. 6, according tovarious embodiments of the present invention. As shown, to generatetruss portion 604, robot system performs a sequence of depositioncircuits. For each deposition circuit, robot system 100 completes a setof passes. In particular, to perform deposition circuit 704, robotsystem 100 completes passes 0, 1, and 2 to deposit material for therespective truss members connected to V5. To perform deposition circuit706, robot system 100 completes passes 3, 4, and 5 to deposit additionalmaterial to those truss members. To perform deposition circuit 708,robot system 100 completes passes 6, 7, and 8 to deposit additionalmaterial. Finally, to perform deposition circuit 708, robot system 100completes passes 9, 10, and 11.

In this manner, robot system 100 builds up the various truss membersassociated with truss portion 604. In some embodiments, robot system 100may complete each truss member before proceeding to another trussmember, thereby performing just one circuit where each truss member isfabricated completely before proceeding to a subsequent truss member.The approach set forth herein may be defined within deposition plan 510discussed above in conjunction with FIG. 5. In addition, robot system100 generally performs the compensation techniques described above inconjunction with FIGS. 3 and 4 in order to generate truss members thatfollow guide curves defined in fabrication data 202.

The various approaches discussed thus far are also described below instepwise fashion in conjunction with FIGS. 8-9.

FIG. 8 is a flow diagram of method steps for fabricating a 3D object viaa closed-loop control process, according to various embodiments of thepresent invention. Although the method steps are described inconjunction with the systems of FIGS. 1-7, persons skilled in the artwill understand that any system configured to perform the method steps,in any order, is within the scope of the present invention.

As shown, a method 800 begins at step 802, where code generator 210within closed-loop control process 200 of robot system 100 receivesfabrication data 202. Fabrication data 202 may define a 3D geometryassociated with 3D object 120 and/or a set of fabrication pathsaccording to which robot system 100 may deposit material to generate 3Dobject 120. At step 804, code generator 210 generates control code 204that configures robot 110 to generate 3D object 120. Control code 204may include G-code or other commands for performing material deposition.At step 806, robot 110 begins depositing material via deposition tool112 based on control code 204.

At step 808, robot system 100 causes optical device 114 to gatheroptical data representing real-time fabrication of 3D object 120. Thatoptical data may include frames 206 of video data and/or point clouddata gathered via laser scanner. In some embodiments, robot system 100also gathers other types of data, including acoustic or vibrational datathat represents the fabrication process. At step 810, computer visionprocessor 220 within closed-loop control process 200 of robot system 100processes the optical data gathered at step 808 to determine one or morelocations where robot 110 deposited material onto 3D object 120. Codegenerator 210 processes these locations to identify deviation ofreal-time fabrication from the fabrication procedure defined infabrication data 202. In embodiments where optical device 114 is a laserscanner, code generator 210 fits point cloud data generated via thatlaser scanner to a model of 3D object 120 using an iterativeclosest-point algorithm, and then evaluates deviations based ondifferences between the point cloud and the model. In evaluating thesedeviations, code generator 210 may train an artificial neural network tocorrelate system-level parameters, such as material feedrate and voltageload, to particular types of deviations. Then, code generator 210 mayanticipate deviations and preemptively compensate accordingly.

At step 812, code generator 210 then generates updated control code 204that compensates for these deviations. Deviations of this variety mayoccur due to PVT variations, among other sources of uncertainty. Inperforming the general approach discussed in conjunction with FIG. 8,robot system 100 may generate complex branched structures, as describedin greater detail below in conjunction with FIG. 9.

FIG. 9 is a flow diagram of method steps for fabricating a branchedstructure based on a set of guide curves, according to variousembodiments of the present invention. Although the method steps aredescribed in conjunction with the systems of FIGS. 1-7, persons skilledin the art will understand that any system configured to perform themethod steps, in any order, is within the scope of the presentinvention.

As shown, a method 900 begins at step 902, where code generator 210within closed-loop control process 200 of robot system 100 processesfabrication data 202 to generate a tree of fabrication paths and a setof nodes joining branches of the tree. Each node in the set of nodes isa vertex where robot system 100 should deposit material when fabricating3D object 120. The fabrication paths between nodes are guide curvesalong which robot system 100 should deposit material. Deposition plan510 of FIG. 5 is one example of a fabrication tree.

At step 904, code generator 210 determines an order with which thebranches of the fabrication tree should be processed to performfabrication of 3D object 120. Code generator 210 generally determinesthe processing order of fabrication tree branches so that material isdeposited in an upward direction and without causing collisions betweenrobot 110 and portions of 3D object 120.

At step 906, robot system 110 performs fabrication of a current branchof the fabrication tree. Upon completion of the current branch, robotsystem 110 advances to step 908 and proceeds to a subsequent branch inthe fabrication tree.

Referring generally to FIGS. 8-9, robot system 100 is configured toimplement the methods 800 and 900 in conjunction with one another inorder to perform closed-loop fabrication of complex branched structures.In doing so, robot system 100 may implement a wide variety of computervision processing techniques in order to track the deposition ofmaterial onto 3D object 120. FIGS. 10-21 describe some of thesetechniques in greater detail.

Tracking Weld Beads with Computer Vision

As a general matter, FIGS. 10-21 are directed toward embodiments ofrobot system 110 where deposition tool 112 is a welder configured todeposit weld beads onto 3D object 120 during fabrication. However, thoseskilled in the art will understand that the techniques described hereincan be adapted to other types of material deposition as well.

FIG. 10 illustrates how the robot system of FIG. 1 deposits a weld beadat a target location, according to various embodiments of the presentinvention. As shown, at time t0 robot system 100 causes deposition tool112 to deposit weld bead 1010 onto 3D object 120. In the embodimentshown, deposition tool 112 is a MIG welder feeding out wire to generateweld beads. At time t1, robot system 100 causes deposition tool 112 toretract, thereby allowing weld bead 1010 to cool. At time t2, robotsystem 100 determines the location of weld bead 1010 on 3D object 120and then computes a target position 1020 for a subsequent weld bead. Indoing so, robot system 100 compensates for any divergence between thetarget location for weld bead 1010 and the actual location where weldbead 1010 is deposited. At time t3, robot system 100 causes depositiontool 112 to begin welding proximate to target location 1020. At time t4,robot system 100 completes welding, thereby generating weld bead 1022.Weld bead 1022 may reside at or near target location 1020.

During the process described above, robot system 100 continuouslycaptures frames 206 of video data that depict the deposition of weldbeads onto 3D object 120. Robot system 100 processes frames 206 todetermine specifically where weld beads are deposited, and moregenerally, how closely the growth of 3D object 120 aligns with targetgeometry for 3D object 120 defined in fabrication data 202. Robot system100 may then compensate for deviations from that target geometry, asdescribed in greater detail below in conjunction with FIG. 11.

FIG. 11 illustrates how the robot system of FIG. 1 adjusts thedeposition of weld beads to compensate for deviations from a guidecurve, according to various embodiments of the present invention. Asshown, robot system 100 may cause deposition tool 112 to fabricate a 3Dobject 1100 using an open-loop process. In addition, robot system 100also causes deposition tool 112 to fabricate 3D object 120 usingclosed-loop control process 200 described above.

With the open-loop process, robot system 100 causes deposition tool 112to follow guide curve 1102 during deposition. Robot system 100 generatesguide curve 1102 prior to deposition based on geometrical constraints1104 and 1106 and cannot change guide curve 1102 during deposition.Geometrical constraints 1104 and 1106 may represent a contour of a 3Dmodel that represents the intended shape of 3D object 1100. However,during deposition, 3D object 1100 may diverge from those geometricalconstraints for various reasons. For example, gravity may cause 3Dobject 1100 to sag in the manner shown, therefore causing the contour of3D object 100 to diverge from geometrical constraints 1104 and 1106.Again, with the open-loop process shown, robot system 100 cannot adjustguide curve 1102 to respond to such divergences.

By contrast, with the closed-loop process shown, robot system 100 iscapable of applying guide curve adjustments in order to respectgeometrical constraints. During fabrication, robot system 100 causesdeposition tool 112 to follow guide curve 312, similar to the open-loopprocess described above. Robot system 100 may generate guide curve 312prior to deposition based on geometrical constraints 1110 and 1112,similar to above. However, during deposition, if 3D object 120 divergesfrom those geometrical constraints, robot system 100 detects thosediverges and computes various relevant parameters, including directionof divergence, magnitude of divergence, gravitational effects, and otherparameters that are described in greater detail below. Based on thesecomputed parameters, robot system 112 adjusts guide curve 112 tocompensate for the corresponding divergences and to keep 3D object 120aligned with geometrical constraints 1110 and 1112.

Robot system 100 implements a variety of logistical techniques in orderto implement the above closed-loop process, including welder monitoringand various coordinate transforms. These approaches are described ingreater detail below in conjunction with FIGS. 12A-12C.

FIGS. 12A-12C illustrate various circuitry and data outputs formonitoring a welding process, according to various embodiments of thepresent invention. As shown in FIG. 12A, a controller 1200 is coupled toa circuit 1202. Controller 1200 may be an Arduino® device or any otherprogrammable hardware. Circuit 1202 is an application-specificintegrated circuit (ASIC) that is configured to measure current consumedby deposition tool 112 during welding. Robot system 100 processes thisdata to estimate various physical characteristics of a weld bead beingdeposited in order to adjust target deposition locations and guidecurves in the manner described above. As shown in FIG. 12B, robot system100 processes the current consumed by deposition tool 112, as measuredby circuit 1202, to establish the linear response of an opto-coupler tothe measured current. Based on this response, robot system 100determines at any given moment whether deposition tool 112 is depositingmaterial. FIG. 12C illustrates the logged weld current over time.

FIG. 13 illustrates a set of coordinate systems associated withdifferent components of the robot system of FIG. 1, according to variousembodiments of the present invention. As shown, robot system 100implements a variety of coordinate systems in order to deposit and tracka weld bead 1300, including coordinate systems 1302, 1304, 1306, 1308,1310, and 1312. The coordinates of 3D object 120 are defined withincoordinate system 1302. The coordinates of a target deposition locationfor weld bead 1300 are defined within coordinate system 1304. Thecoordinates of an actual deposition location (as determined via opticaldevice 114) are defined within coordinate system 1306. The coordinatesof optical device 114 are defined within coordinate system 1308.Coordinates associated with robot 110 are defined within coordinatesystem 1310. World space coordinates are defined within coordinatesystem 1312. Robot system 100 may transform any of the coordinatesdiscussed thus far into any of the other coordinate systems discussed.

Robot system 100 implements the coordinate systems and transformsdiscussed above in order to process sensor data related to thedeposition process. Robot system 100 also relies on these coordinatetransforms to position optical device 114, as described in greaterdetail below in conjunction with FIGS. 14-15.

FIG. 14 illustrates relative positioning between an optical device and a3D object under weld, according to various embodiments of the presentinvention. As shown, fabrication tool 112 deposits weld beads alongguide curve 312 to fabricate 3D object 120. Robot system 100 isconfigured to transform coordinates between coordinate system 1304 and1308 in order to maintain specific relative positioning between opticaldevice 114 and a location on 3D object 120 where welding occurs. Inparticular, robot system 100 positions optical device 112 so that theaxis along which optical device 114 captures optical data isperpendicular to the axis along which deposition tool 112 feeds weldingmaterial. Robot system 100 may also rotate optical device 114 tomaintain a consistent alignment relative to deposition tool 112. Thispositioning allows frames 206 of video data captured by optical device114 to show the deposition process in a manner that does not requirecomputer vision processor 220 to re-orient frames 206. Robot system 100may also position optical device 114 relative to a gravity vector, asdescribed in greater detail below in conjunction with FIG. 15.

FIG. 15 illustrates how the robot system of FIG. 1 positions an opticaldevice relative to a 3D object under weld to improve data capture,according to various embodiments of the present invention. As shown,robot system 100 may position optical device 114 anywhere along orbit1500. However, in order to record potential sagging due to gravity,robot system 100 may position optical device 114 perpendicular to agravity vector. This alignment allows optical device 114 to captureframes 206 of video data that indicate when 3D object diverges fromguide curve 312. FIGS. 16-18 discuss how computer vision processor 220processes frames 206 of video data to track deposited weld beads.

FIG. 16 illustrates how the robot system of FIG. 1 locates a previouslydeposited weld bead, according to various embodiments of the presentinvention. As shown, computer vision processor 220 processes a frame 206of video data to identify a search frame 1600 within which materialdeposition occurs. Within search frame 1600, computer vision processorsearches for groups of pixels that match search template 1610. Searchtemplate 1610 may be a conventional computer vision template thatindicates a target image to locate within a search frame. In thisinstance, search template 1610 illustrates a characteristic weld beadduring deposition.

FIG. 17 illustrates how the robot system of FIG. 1 determines adeposition location for a weld bead, according to various embodiments ofthe present invention. As shown, robot system 100 causes deposition tool112 to deposit a weld bead 1700 onto 3D object 120. Subsequently, robotsystem 100 determines a target location 1710 for a subsequent weld bead.Robot system 100 may determine target location 1710 within a searchframe 1600(0). Robot system 100 then deposits a weld bead 1712 at ornear target location 1710. In practice, weld bead 1712 is typicallyoffset from target location 1710 by an incremental amount in the X, Y,and/or Z directions due to fabrication variations. Robot system 100processes search frames 1600(0) and 1600(1) to determine thisincremental amount, and then adjusts the guide curve followed by robotsystem 100 accordingly to compensate for these offsets, as described ingreater detail below in conjunction with FIG. 18.

FIG. 18 illustrates how the robot system of FIG. 1 follows a guide curvebased on previously deposited weld beads, according to variousembodiments of the present invention. As shown, robot system 100 causesdeposition tool 112 to follow guide curve 312 during deposition of weldbeads, and optical device 114 captures frames 206 of video data, asdiscussed previously. Once deposition tool 112 has deposited weld bead1712 proximate to target location 1710, code generator 210 within robotsystem 100 determines the distance between target location 1710 and acomputed centroid location of the deposited weld bead. Code generator210 then evaluates equations 1800 and 1802 in conjunction with oneanother in order to update control code 204, thereby modifyingfabrication of 3D object 120 based on feedback generated duringdeposition.

Equation 1800 includes three terms that generally govern (i) the rate atwhich deposited weld beads converge or diverge with corresponding targetlocations, (ii) the degree with which that convergence or divergencecompares to a given region, and (iii) the effects of gravity relative todeposition angle. Equation 1800 evaluates to a tangent vector alongguide curve 312. Guide curve 312 may be dynamically defined by suchvectors over many evaluations of equation 1800. Thus, by evaluatingequation 1800 continuously, robot system 100 modifies the directionalong which deposition tool 312 deposits weld beads. In addition,equation 1802 may be evaluated to scale the vector generated viaequation 1800 based on previously computed vectors and based on aninfluence parameter. With this approach, robot system 100 may smoothguide curve 312 so that large divergences between weld beads and targetlocations do not cause correspondingly large changes to guide curve 312.In one embodiment, robot system 100 maintains separate a print curvethat is separate from guide curve, and applies modifications based onequations 1800 and 1802 to print curve in order to better align printcurve with guide curve.

During the deposition process, robot system 100 outputs a collection ofreal-time data discussed, by way of example, below in conjunction withFIG. 19.

FIG. 19 is a screen capture that illustrates the real-time output of therobot system of FIG. 1 during welding, according to various embodimentsof the present invention. As shown, screen capture 1900 shows thedeposition of weld beads onto 3D object 120 and also outputs other dataand metadata related to material deposition. In one embodiment, robotsystem 100 processes any and all of the data shown in screen capture1900 to establish one or more trends that represent the welding processover time. Robot system 100 may then combine this trend data with newlyacquired real-time data to compensate for unexpected process variations.

Referring generally to FIGS. 10-19, the techniques described in thesefigures are also described in stepwise fashion below in conjunction withFIGS. 20-21.

FIG. 20 is a flow diagram of method steps for fabricating a 3D objectbased on real-time optical data, according to various embodiments of thepresent invention. Although the method steps are described inconjunction with the systems of FIGS. 1-7 and 10-19, persons skilled inthe art will understand that any system configured to perform the methodsteps, in any order, is within the scope of the present invention.

As shown, a method 2000 begins at step 2002, where robot system 100generates a guide curve that includes a sequence of vertices and acorresponding sequence of tangent vectors. Guide curve 312 shown in FIG.3 is one example of a guide curve. Robot system 100 may generate theguide curve based on fabrication data 202. At step 2004, robot system100 identifies a current vertex on the guide curve. At step 2006, robotsystem 100 causes deposition tool 112 to deposit a portion of materialproximate to the current vertex.

At step 2008, optical device 114 captures frames 206 of video dataassociated with the deposition performed at step 2006. At step 2010,computer vision processor 220 processed frames 206 to identify 3Dcoordinates where the portion of material was deposited at step 2006. Indoing so, computer vision processor 220 implements the techniquesdescribed above in conjunction with FIGS. 16-18. Computer visionprocessor 220 also determines a heading vector associated with those 3Dcoordinates. At step 2012, code generator 210 within robot system 100compares the 3D location with the current vertex to determine a distancebetween that location and the vertex. At step 2014, code generator 210compares the heading vector with a tangent vector corresponding to thecurrent vertex. At step 2016, code generator 210 computes a vector basedon the location comparison performed at step 2012, the vector comparisonperformed at step 2014, a gravity vector, and one or more previousvertices. In doing so, robot system 100 may evaluate equations 1800 and1802.

Step 2010 of the method 2000 may be implemented via a method describedin greater detail below in conjunction with FIG. 21.

FIG. 21 is a flow diagram of method steps for determining a weldlocation based on real-time optical data, according to variousembodiments of the present invention. Although the method steps aredescribed in conjunction with the systems of FIGS. 1-7 and 10-20,persons skilled in the art will understand that any system configured toperform the method steps, in any order, is within the scope of thepresent invention.

As shown, a method 2100 begins at step 2102, where computer visionprocessor 220 receives a frame 206 of video data from optical device114. At step 2102, computer vision processor 220 identifies a searchframe within the frame of video data. At step 2104, computer visionprocessor 220 searches within the search frame identified at step 2102for a search template, and identifies a set of pixels within the searchframe that match the search template. At step 2108, computer visionprocessor determines a deposition location within the search frame basedon the template match. In doing so, computer vision processor 220 maydetermine a centroid location for a weld bead depicted in the searchframe. Persons skilled in the art will understand that the method 2100represents only one approach to determining a weld location, and thatother approaches may also be possible.

Referring generally to FIGS. 1-21, the techniques described herein allowrobot system 100 to perform highly complicated fabrication operations togenerate complex 3D objects. Because such operations cannot be performedwith conventional 3D printers, such 3D objects cannot be created withconventional 3D printing techniques either. FIGS. 22A-27 describevarious unconventional printing techniques made possible by robot system100.

Unconventional Deposition Techniques

FIGS. 22A-22B illustrate the robot system of FIG. 1 depositing materialalong non-horizontal layers of a 3D object, according to variousembodiments of the present invention. As shown in FIG. 22A, robot system100 causes deposition tool 112 to deposit a layer 2202 of material whenfabricating a 3D object 2200. A conventional 3D printer would only beable to deposit another horizontal layer having equal thickness andcontinuous cross-section compared to layer 2202.

However, as shown in FIG. 22B, robot system 100 is capable of depositinga layer 2204 that is not horizontal to layer 2202 and has across-section with varying thickness. Robot system 100 may perform suchdeposition by varying the flow rate of material used for depositionand/or following guide curves that define layer 2204, while also varyingthe angle of deposition tool 112 relative to horizontal.

FIGS. 23A-23B illustrate the robot system of FIG. 1 depositing materialalong non-parallel layers of a 3D object, according to variousembodiments of the present invention. As shown in FIG. 23A, robot system100 causes deposition tool 112 to deposit layers 2302, 2304, 2306, and2308 when fabricating a 3D object 2300. A conventional 3D printer canonly deposit additional layers on top of layer 2308.

However, as shown in FIG. 23B, robot system 100 is capable of depositingadditional layers 2310, 2312, 2314, 2316, and 2318 at off-horizontalangles. Robot system 100 may perform such deposition based on abranching deposition plan, such as deposition plan 510 shown in FIG. 5.

FIGS. 24A-24B illustrate the robot system of FIG. 1 depositing materialalong non-planar layers of a 3D object, according to various embodimentsof the present invention. As shown in FIG. 24A, robot system 100 causesdeposition tool 112 to deposit layers 2402, 2404, 2406, and 2408 tofabricate 3D object 2400. Unlike conventional 3D printers, robot system100 is capable of depositing layers that are non-planar, as is shown.

As shown in FIG. 24B, robot system 100 fabricates non-planar layers bysweeping deposition tool 112 from position 2410 to position 2414 acrossan arc 2414. To implement this technique, robot system 100 may follow aguide curve that traverses from vertex 2408(0) to vertex 2408(1) alongarc 2414.

FIG. 25 illustrates the robot system of FIG. 1 depositing material alongnon-horizontal, non-parallel, and non-planar layers of a 3D object,according to various embodiments of the present invention. As shown,robot system 100 causes deposition tool 312 to fabricate a 3D object2500 that includes multiple non-planar, non-horizontal, and non-parallellayers 2502, 2504, and 2506. 3D object 2500 has a central axis 2510.Because this central axis is curved, layers 2502, 2504, and 2506 vary inthickness between side 2512 and 2514 of 3D object 2500. As fabricationprogresses and 3D object 2500 grows, that object will begin to overhangtowards side 2514. Unlike conventional 3D printers, though, robot system100 does not need to provide support for this overhang. In oneembodiment, robot system 100 fabricates 3D object 2500 by generating onecontinuous spiraling layer aligned with central axis 2510.

FIGS. 26A-26B illustrate the robot system of FIG. 1 adjusting afabrication plan in real-time based on local deviations in a 3D object,according to various embodiments of the present invention. As shown,robot system 100 causes deposition tool 112 to deposit layers ofmaterial to fabricate 3D object 2600. Optical device 114 detects adimple 2602 in a previous layer of 3D object 2600. However, 3D object2600 is subject to the constraint that top surface 2604 of 3D object2600 must have an angle 2610 relative to horizontal. In order to adhereto this constraint, robot system 100 dynamically accounts for dimple2602 in the manner shown in FIG. 26B.

As shown in FIG. 26B, robot system 100 adjusts deposition rate 2610 toincrease proximate to dimple 2602 and decrease in other places. Forexample, deposition rate 2610(2) is greater than deposition rates2610(1) and 2610(3) and much greater than deposition rates 2610(0) and2610(4), as indicated by arrow thickness. Thus, progressing from left toright, deposition rate 2610 increases when approaching dimple 2602 andthen decreases afterward. Robot system 100 determines deposition rates2610 based on frames of video data gathered by optical device 114 andprocessed by computer vision processor 220.

FIG. 27 is a flow diagram of method steps for fabricating a 3D objectusing different deposition techniques, according to various embodimentsof the present invention. Although the method steps are described inconjunction with the systems of FIGS. 1-7, 10-20, and 22A-26B, personsskilled in the art will understand that any system configured to performthe method steps, in any order, is within the scope of the presentinvention.

As shown, a method 2700 begins at step 2702, where code generator 210within closed-loop control cycle 200 of robot system 100 receivesfabrication data 202 that defines a fabrication procedure. At step 2704,code generator 210 processes fabrication data 202 to generate a set ofguide curves along which robot system 100 deposits material. At step2706, robot system 100 causes deposition tool 112 to deposit materialalong a first path having a first orientation relative to horizontal andaligned with a first axis. At step 2708, robot system 100 causesdeposition tool 112 to deposit material along a second path having asecond orientation and with a deposition rate that changes along thesecond path. In this manner, robot system may fabricate 3D object 2200shown in FIG. 22.

At step 2710, robot system 100 causes deposition tool 112 to depositmaterial along a third path having a third orientation relative tohorizontal and aligned with a second axis having a first angle relativeto the first axis. In this manner, robot system 100 may fabricate 3Dobject 2300 shown in FIG. 23. At step 2712, robot system 100 causesdeposition tool 112 to deposit material along a fourth path that isnon-planar by sweeping deposition tool 112 from a start angle to afinish angle along a first arc that is aligned with the fourth path.Robot system 100 implements step 2710 to generate 3D object 2400 of FIG.24.

By performing individual steps of the method 2700, robot system 100 canfabricate any of the shapes shown in FIGS. 22A-24B. In addition, byperforming all steps in conjunction with one another, robot system 100may fabricate complex objects such as 3D object 2500 shown in FIG. 25.

FIG. 28 is a flow diagram of method steps for fabricating a 3D object tomeet a set of design objectives, according to various embodiments of thepresent invention. Although the method steps are described inconjunction with the systems of FIGS. 1-7, 10-20, and 22A-26B, personsskilled in the art will understand that any system configured to performthe method steps, in any order, is within the scope of the presentinvention.

As shown, a method 2800 begins at step 2802, where code generator 210within closed-loop control cycle 200 of robot system 100 receivesfabrication data 202 that defines a fabrication procedure, similar tostep 2702 of the method 2700.

At step 2804, code generator 210 within closed-loop control process 200of robot system 100 processes fabrication data 202 to identify a set ofdesign objectives associated with a 3D object to be fabricated based onthe fabrication procedure. The design objectives indicate that certainportions of the 3D object have a specific shape, as described by way ofexample in conjunction with FIG. 26.

At step 2804, code generator 210 processes fabrication data 202 togenerate a set of paths for fabricating the 3D object. At step 2806,robot system 100 causes deposition tool 112 to deposit material onto afirst substrate of the 3D object along a first path in the set of paths.At step 2808, robot system 100 detects variations in the first substrateand, in response to those variations, adjusts deposition of the materialalong the first path to compensate. In one embodiment, robot system 100implements a laser scanner to detect variations in the first substrate.Dimple 2602 shown in FIGS. 26A-26B is one example of a variation.According to this technique, robot system 100 may meet the designobjectives set forth in fabrication data 202 despite local variations inthe 3D object.

In sum, a robot system is configured to fabricate three-dimensional (3D)objects using closed-loop, computer vision-based and/or realitycapture-based control. The robot system initiates fabrication based on aset of fabrication paths along which material is to be deposited. Duringdeposition of material, the robot system captures video data or 3D pointcloud data and processes that data to determine the specific locationswhere the material is deposited. Based on these locations, the robotsystem adjusts future deposition locations to compensate for deviationsfrom the fabrication paths. Additionally, because the robot systemincludes a 6-axis robotic arm, the robot system can deposit material atany location, along any pathway, or across any surface. Accordingly, therobot system is capable of fabricating a 3D object with multiplenon-parallel, non-horizontal, and/or non-planar layers.

At least one advantage of the techniques described above is that therobot system is capable of tolerating and compensating for a widevariety of potential faults, thereby increasing the likelihood offabricating a 3D object that meets design specifications. Thosepotential faults may relate to process-voltage-temperature (PVT)variations, material composition inconsistencies, and unexpected heattransfer and/or cooling effects, among others. In addition, the robotsystem is capable of fabricating 3D objects with a much wider variety ofgeometries compared to conventional 3D printers, including geometriesthat include overhangs and geometries with complex branching structures.

The descriptions of the various embodiments have been presented forpurposes of illustration, but are not intended to be exhaustive orlimited to the embodiments disclosed. Many modifications and variationswill be apparent to those of ordinary skill in the art without departingfrom the scope and spirit of the described embodiments.

Aspects of the present embodiments may be embodied as a system, methodor computer program product. Accordingly, aspects of the presentdisclosure may take the form of an entirely hardware embodiment, anentirely software embodiment (including firmware, resident software,micro-code, etc.) or an embodiment combining software and hardwareaspects that may all generally be referred to herein as a “module” or“system.” Furthermore, aspects of the present disclosure may take theform of a computer program product embodied in one or more computerreadable medium(s) having computer readable program code embodiedthereon.

Any combination of one or more computer readable medium(s) may beutilized. The computer readable medium may be a computer readable signalmedium or a computer readable storage medium. A computer readablestorage medium may be, for example, but not limited to, an electronic,magnetic, optical, electromagnetic, infrared, or semiconductor system,apparatus, or device, or any suitable combination of the foregoing. Morespecific examples (a non-exhaustive list) of the computer readablestorage medium would include the following: an electrical connectionhaving one or more wires, a portable computer diskette, a hard disk, arandom access memory (RAM), a read-only memory (ROM), an erasableprogrammable read-only memory (EPROM or Flash memory), an optical fiber,a portable compact disc read-only memory (CD-ROM), an optical storagedevice, a magnetic storage device, or any suitable combination of theforegoing. In the context of this document, a computer readable storagemedium may be any tangible medium that can contain, or store a programfor use by or in connection with an instruction execution system,apparatus, or device.

Aspects of the present disclosure are described above with reference toflowchart illustrations and/or block diagrams of methods, apparatus(systems) and computer program products according to embodiments of thedisclosure. It will be understood that each block of the flowchartillustrations and/or block diagrams, and combinations of blocks in theflowchart illustrations and/or block diagrams, can be implemented bycomputer program instructions. These computer program instructions maybe provided to a processor of a general purpose computer, specialpurpose computer, or other programmable data processing apparatus toproduce a machine, such that the instructions, which execute via theprocessor of the computer or other programmable data processingapparatus, enable the implementation of the functions/acts specified inthe flowchart and/or block diagram block or blocks. Such processors maybe, without limitation, general purpose processors, special-purposeprocessors, application-specific processors, or field-programmableprocessors or gate arrays.

The flowchart and block diagrams in the figures illustrate thearchitecture, functionality, and operation of possible implementationsof systems, methods and computer program products according to variousembodiments of the present disclosure. In this regard, each block in theflowchart or block diagrams may represent a module, segment, or portionof code, which comprises one or more executable instructions forimplementing the specified logical function(s). It should also be notedthat, in some alternative implementations, the functions noted in theblock may occur out of the order noted in the figures. For example, twoblocks shown in succession may, in fact, be executed substantiallyconcurrently, or the blocks may sometimes be executed in the reverseorder, depending upon the functionality involved. It will also be notedthat each block of the block diagrams and/or flowchart illustration, andcombinations of blocks in the block diagrams and/or flowchartillustration, can be implemented by special purpose hardware-basedsystems that perform the specified functions or acts, or combinations ofspecial purpose hardware and computer instructions.

While the preceding is directed to embodiments of the presentdisclosure, other and further embodiments of the disclosure may bedevised without departing from the basic scope thereof, and the scopethereof is determined by the claims that follow.

The invention claimed is:
 1. A computer-implemented method forfabricating a three-dimensional (3D) object, the method comprising:depositing a first weld bead at a first deposition location on the 3Dobject; capturing first optical data from the first deposition locationwhile depositing the first weld bead; identifying a first image of thefirst weld bead within the first optical data; determining coordinatesof the first deposition location based on the first image; anddepositing a second weld bead at a second location on the 3D objectbased on the coordinates of the first deposition location.
 2. Thecomputer-implemented method of claim 1, wherein the first optical datacomprises a search frame, and identifying the first image comprisessearching the search frame based on a search template that includes acharacteristic image of a weld bead during deposition.
 3. Thecomputer-implemented method of claim 1, wherein determining coordinatesof the first deposition location comprises identifying a centroidlocation within the first image of the first weld bead.
 4. Thecomputer-implemented method of claim 1, wherein capturing the firstoptical data comprises positioning an optical device relative to adeposition tool configured to deposit the first weld bead.
 5. Thecomputer-implemented method of claim 4, wherein positioning the opticaldevice comprises causing the optical device to point in a direction thatis perpendicular to a direction in which the deposition tool depositsthe first weld bead.
 6. The computer-implemented method of claim 4,wherein positioning the optical device comprises causing the opticaldevice to point in a direction that is perpendicular to a directionassociated with a gravity vector.
 7. The computer-implemented method ofclaim 1, wherein determining the second location comprises: generating aheading vector that indicates a direction in which the first weld beadis deposited; generating a pull vector between the first depositionlocation and a target location associated with the first depositionlocation; combining the heading vector with the pull vector to generatea combined vector; and evaluating a rate of change of the combinedvector to determine the second location.
 8. The computer-implementedmethod of claim 7, wherein determining the second location furthercomprises comparing a distance between the first deposition location andthe target location to a radius of influence to generate a first ratio.9. The computer-implemented method of claim 8, wherein determining thesecond location further comprises generating a guide vector based on therate of change of the combined vector, the first ratio, and a gravityvector, wherein the second location resides along the guide vector. 10.A non-transitory computer-readable medium that, when executed by aprocessor, causes the processor to fabricate a three-dimensional (3D)object by performing the steps of: depositing a first weld bead at afirst deposition location on the 3D object; capturing first optical datafrom the first deposition location while depositing the first weld bead;identifying a first image of the first weld bead within the firstoptical data; determining coordinates of the first deposition locationbased on the first image; and depositing a second weld bead at a secondlocation on the 3D object based on the coordinates of the firstdeposition location.
 11. The non-transitory computer-readable medium ofclaim 10, wherein the first optical data comprises a search frame, andthe step of identifying the first image comprises searching the searchframe based on a search template that includes a characteristic image ofa weld bead during deposition.
 12. The non-transitory computer-readablemedium of claim 10, wherein the step of determining coordinates of thefirst deposition location comprises identifying a centroid locationwithin the first image of the first weld bead.
 13. The non-transitorycomputer-readable medium of claim 10, wherein the step of capturing thefirst optical data comprises positioning an optical device relative to adeposition tool configured to deposit the first weld bead.
 14. Thenon-transitory computer-readable medium of claim 13, wherein the step ofpositioning the optical device comprises causing the optical device topoint in a direction that is perpendicular to a direction in which thedeposition tool deposits the first weld bead.
 15. The non-transitorycomputer-readable medium of claim 13, wherein the step of positioningthe optical device comprises causing the optical device to point in adirection that is perpendicular to a direction associated with a gravityvector.
 16. The non-transitory computer-readable medium of claim 10,wherein the step of determining the second location comprises:generating a heading vector that indicates a direction in which thefirst weld bead is deposited; generating a pull vector between the firstdeposition location and a target location associated with the firstdeposition location; combining the heading vector with the pull vectorto generate a combined vector; and evaluating a rate of change of thecombined vector to determine the second location.
 17. The non-transitorycomputer-readable medium of claim 16, wherein the step of determiningthe second location further comprises comparing a distance between thefirst deposition location and the target location to a radius ofinfluence to generate a first ratio.
 18. The non-transitorycomputer-readable medium of claim 10, wherein the first weld bead andthe second weld bead reside on a first branch of the 3D object, andfurther comprising the step of depositing a third weld bead on a secondbranch of the 3D object.
 19. A system, comprising: a memory thatincludes a control application; and a processor coupled to the memoryand configured to: cause a deposition tool to deposit a first weld beadat a first deposition location on the 3D object, capture first opticaldata from the first deposition location while depositing the first weldbead, identify a first image of the first weld bead within the firstoptical data, determine coordinates of the first deposition locationbased on the first image, and cause the deposition tool to deposit asecond weld bead at a second location on the 3D object based on thecoordinates of the first deposition location.
 20. The system of claim19, wherein the processor, upon executing the control application, isconfigured to: cause the deposition tool to deposit the first weld bead;capture the first optical data; identify the first image of the firstweld bead; determine the coordinates of the first deposition location;and cause the deposition tool to deposit the second weld bead.